Light-transmissive foam composition and process

Abstract

A polyolefin foam having improved light-transmittance comprises an average cell size of about 70 microns to about 500 microns; a total cell wall thickness to gauge ratio of between about 0.15 to about 0.55; a basis weight of about 0.00005 lb/in.sup.2 to about 0.00050 lb/in.sup.2; an L color solid value of about 95 to about 45; and a light transmittance of about 10% to about 50% according to JIS K 7361-1. A process for producing a polyolefin foam having improved light-transmittance comprises extruding a foamable sheet at a pressure from about 1 psi to about 55 psi, and foaming the foamable sheet with a foaming agent having an average diameter of about 10 to about 25 microns to produce a foam having a light transmittance of about 10% to about 50% according to JIS K 7361-1.

Claims

1. A polyolefin foam sheet, comprising: an average cell size of about 70 microns to about 500 microns; a total cell wall thickness to sheet gauge ratio of between about 0.15 to about 0.55; a basis weight of about 0.00005 lb/in.sup.2 to about 0.00050 lb/in.sup.2; an L color solid value of about 95 to about 45; and a light transmittance of about 10% to about 50% according to JIS K 7361-1.

2. The polyolefin foam sheet of claim 1, wherein the average cell size is about 80 microns to about 465 microns.

3. The polyolefin foam sheet of claim 1, wherein the average cell size is about 195 microns to about 465 microns.

4. The polyolefin foam sheet of claim 1, wherein the basis weight is about 0.00008 lb/in.sup.2 to about 0.00043 lb/in.sup.2.

5. The polyolefin foam sheet of claim 1, wherein the basis weight is about 0.00008 lb/in.sup.2 to about 0.00027 lb/in.sup.2.

6. The polyolefin foam sheet of claim 1, wherein the L color solid value is about 91 to about 65.

7. The polyolefin foam sheet of claim 1, wherein the light transmittance is about 15% to about 45%.

8. The polyolefin foam sheet of claim 1, wherein the light transmittance is about 15% to about 35%.

9. The polyolefin foam sheet of claim 1, wherein the total cell wall thickness to sheet gauge ratio is about 0.18 to about 0.50.

10. The polyolefin foam sheet of claim 1, wherein the total cell wall thickness to sheet gauge ratio is about 0.22 to about 0.50.

11. The polyolefin foam sheet of claim 1, further comprising one or more resins selected from the group consisting of: low density polyethylene (LDPE), linear low density polyethylene (LLDPE); ethylene vinyl acetate (EVA); polypropylene (PP); ethylene propylene diene monomer (EPDM), thermoplastic olefin (TPO), thermoplastic elastomer (TPE), and rubber.

12. A process for producing a polyolefin foam, comprising: extruding a foamable sheet at an air pressure from about 1 psi to about 55 psi; and foaming the foamable sheet with a foaming agent having an average diameter of about 10 to about 25 microns to produce a foam having a light transmittance of about 10% to about 50% according to JIS K 7361-1.

13. The process of claim 12, further comprising extruding the foamable sheet at an air pressure from about 2 psi to about 30 psi.

14. The process of claim 12, further comprising extruding the foamable sheet at an air pressure from about 25 psi to about 30 psi.

15. The process of claim 12, further comprising extruding the foamable sheet at atmospheric pressure.

16. The process of claim 12, further comprising foaming the foamable sheet with a foaming agent having an average diameter of about 12 microns to about 20 microns.

17. The process of claim 12, wherein the foaming agent comprises azodicarbonamide (ADCA).

18. The process of claim 12, further comprising crosslinking the foamable sheet prior to foaming the foamable sheet.

19. The process of claim 12, wherein the light transmittance is about 15% to about 45%.

20. The polyolefin foam of claim 12, wherein the light transmittance is about 15% to about 35%.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a graph depicting % light transmittance vs. basis weight of foam.

(2) FIG. 2 is a graph depicting % light transmittance vs. basis weight and colors of foam.

(3) FIGS. 3A, 3B and 3C are graphs depicting % light transmittance vs. L, a, and b solid color values of foam, respectively.

(4) FIG. 4A is a graph depicting % light transmittance versus cell size of foam.

(5) FIG. 4B is a graph depicting foam cell size versus foam extrusion air pressure.

(6) FIG. 4C is a graph depicting % light transmittance versus foam extrusion air pressure.

(7) FIG. 5A is a graph depicting % light transmittance versus total wall thickness to gauge ratio of foam.

(8) FIG. 5B is a graph depicting total wall thickness to gauge ratio versus foam extrusion air pressure.

(9) FIG. 6 is a graph depicting foam extrusion air pressure versus L, a, b scale colors of the foam.

(10) FIG. 7A is a graph depicting foam cell size versus foaming agent particle diameter.

(11) FIG. 7B is a graph depicting total wall thickness to gauge ratio versus foaming agent particle diameter.

(12) FIG. 7C is a graph depicting % light transmittance versus foaming agent particle diameter.

(13) FIG. 8A is a graph depicting cell size of polypropylene trial foam samples.

(14) FIG. 8B is a graph depicting wall thickness to gauge ratio of polypropylene trial foam samples.

(15) FIG. 8C is a graph depicting % light transmittance of polypropylene trial foam samples.

(16) FIG. 9 is a graph depicting % light transmittance versus basis weight of polypropylene trial foam samples.

DETAILED DESCRIPTION

(17) Disclosed herein is a polyolefin foam composition and method of producing the same, wherein the foam comprises improved light-transmissive properties suitable for a wide variety of applications requiring the transmission of light through the foam, including illuminated displays and ambient lighting for the interior trim of vehicles, for example. A foam of the present disclosure may be considered as “light-transmissive” if at least a portion of incident visible light is transmitted through the foam and can readily be detected, as in, for example, semi-transparent and translucent foams.

(18) Polymers or resins suitable for use in a foamable sheet include but are not limited to low density polyethylene (LDPE), linear low density polyethylene (LLDPE); ethylene vinyl acetate (EVA); polypropylene (PP); ethylene propylene diene monomer (EPDM), thermoplastic olefin (TPO), thermoplastic elastomer (TPE), and rubber. Individual resins may be selected for the light-transmissive foam, as well as blends of two or more resins. Suitable foaming agents may include azodicarbonamide (ADCA), for example.

(19) In one aspect, a polyolefin foam having improved light transmittance may be produced to comprise an average cell size of about 70 microns to about 500 microns; preferably about 80 microns to about 465 microns, and more preferably about 195 microns to about 465 microns, as well as any combination of the aforementioned upper and lower limits of those ranges.

(20) In another aspect, the polyolefin foam having improved light transmittance may be produced to comprise a total cell wall thickness to gauge ratio of between about 0.15 to about 0.55; preferably between about 0.18 to about 0.50; and more preferably between about 0.22 to about 0.50, as well as any combination of the aforementioned upper and lower limits of those ranges.

(21) In another aspect, the polyolefin foam having improved light transmittance may be produced to comprise a basis weight of about 0.00005 lb/in.sup.2 to about 0.00050 lb/in.sup.2, more preferably between about 0.00008 lb/in.sup.2 to about 0.00043 lb/in.sup.2, and most preferably between about 0.00008 lb/in.sup.2 to about 0.00027 lb/in.sup.2.

(22) In another aspect, the polyolefin foam having improved light transmittance may be produced to comprise an L color solid value of about 95 to about 45, or about 91 to about 65, but most preferably as close to 100 as possible.

(23) In another aspect, the polyolefin foam having improved light transmittance may be produced to comprise a light transmittance of about 10% to about 50%, about 15% to about 45%, about 15% to about 35%, about 20% to about 40%, or about 25% to about 35%, as well as any combination of the aforementioned upper and lower limits of those ranges, but most preferably as high as possible.

(24) In another aspect, a process for producing a polyolefin foam having improved light-transmittance comprises extruding a foamable sheet at a pressure from about 1 psi to about 55; preferably at about 2 psi to about 30 psi, and more preferably at about 25 psi to about 30 psi, or alternatively at atmospheric pressure, to produce a foam having a light transmittance of about 10% to about 50%, about 15% to about 45%, about 15% to about 35%, about 20% to about 40%, or about 25% to about 35%, as well as any combination of the aforementioned upper and lower limits of those ranges, but most preferably as high as possible.

(25) In another aspect, a process for producing a polyolefin foam having improved light-transmittance comprises foaming a foamable sheet with a foaming agent having an average particle diameter of about 10 to about 25 microns, and more preferably about 12 microns to about 20 microns, to produce a foam having a light transmittance of about 10% to about 50%, about 15% to about 45%, about 15% to about 35%, about 20% to about 40%, about 25% to about 35%, as well as any combination of the aforementioned upper and lower limits of those ranges, but most preferably as high as possible.

EXPERIMENTAL METHOD

(26) The light transmittance of various foam samples prepared according to the description below was measured according to the Japanese Industrial Standard JIS K 7361-1 (determination of the total luminous transmittance of transparent materials) utilizing a Konica Minolta Benchtop Spectrophotometer CM-3600A. JIS K 7361-1 is based upon ISO 13468-1. Foam color was measured according to the standardized CIELAB color space (also known as CIE L*a*b* color space) as defined by the International Commission on Illumination, utilizing a HunterLab color spectrophotometer.

(27) The following formulations of TABLE 1A were used to prepare the foam samples used in the experiments described further below.

(28) TABLE-US-00001 TABLE 1A White Cream Cream White PE PP 1 PP 2 PP PP Trials LLDPE 1 10-40 20-40 10-40 LLDPE 2 AR AR LLDPE 3  5-15  5-10  5-15 LLDPE 4 20-50 LDPE 100 h-PP 1 10-40 h-PP 2 10-25 Random copolymer 50-80 PP 1 Random copolymer 30-60 PP 2 Random copolymer 50-80 PP 3 TPE 10-40 Crosslinking Agent 2-5 2-5 2-5 1 Crosslinking Agent 1-5 2 Phenol Based AO 0.5-1.5 0.5-1.5 0.5-1.5 0.5-1.5 Sulfur Based AO 0.1-1 0.5-1.5 0.5-1.5 0.5-1.5 0.5-2.sup.  Heat Stabilizer 1 0.5-1.sup.  0.5-2.sup.  Heat Stabilizer 2 0.1-1 0.5-1.5 0.5-1.5 0.5-2.sup.  Foaming Agent 1 AR AR AR Foaming Agent 2 AR AR Foaming Agent 3 AR FA Activator 1 .sup. 0.5-1.5 FA Activator 2 .sup. 0.5-1.5 Lubricant 0.1-1

(29) Wherein LLDPE is linear low-density polyethylene, h-PP is a homopolymer polypropylene, TPO is a thermoplastic polyolefin, TPE is a thermoplastic elastomer, AO is an antioxidant, and foaming agent (FA) such as azodicarbonamide was used in an amount as required (AR) to achieve desired foam densities tested in the Examples below as may be appreciated by a person having ordinary skill in the art. The cream versus white color was achieved through choice of heat stabilizer which affected the basic color of the foam.

(30) The foam formulation for each tested sample was blended and extruded through a single or twin-screw extruder and a sheet die at a temperature higher than the melt temperature of the polymers and lower than an activation temperature of the foaming agent to produce a foamable sheet. Extrusion was performed under a vacuum or below atmospheric pressure (atm) for all samples unless noted otherwise, such as denoted “Open Air” which are extruded at atmospheric pressure, or as denoted with a psi exceeding atmospheric pressure in the Examples below. Suitable air pressures for less than 1 atm extrusion may be from about 1 to about 14 psi for example (wherein 1 atm=14.7 psi).

(31) The extruded sheet was physically irradiated with an electron beam to physically crosslink the foam at a desired gel content, preferably about 30% to about 65%, and then the sheet was foamed in a foaming oven at or above an activation temperature of the foaming agent to yield the foamed samples for testing.

(32) The physical and performance properties of the produced foam samples were measured according to industry-standard specifications commonly used in automotive interior foams, for example, with the results shown in TABLE 1B below, with MD measured in the machine direction of foam extrusion and CM measured in the cross machine direction of foam extrusion. Draw Ratio refers to a property of the foam with respect to thermoforming, and Orange Peel refers to surface degradation during thermoforming, as may be appreciated by someone of ordinary skill in the industry.

(33) TABLE-US-00002 TABLE 1B Open Air Open Air Open Air Cream PP White PP White PP White PP 2 White PP 3 (<1 atm) (<1 atm) (@ 1 atm) (@ 1 atm) (@ 1 atm) Gauge (in) 0.117  0.119  0.122  0.117  0.063 Density (pcf) 4.18 3.90 3.78 2.66 4.33 Comp Defl 25% (psi) 9.5 8.5 8.3 4.0 10.2 Gel % 48.1%  49.2%  48.7%  49.4%  44.4%  Tensile @ 23° C. MD 15.2 12.1 9.9 7.3 11.7 (kgf/cm{circumflex over ( )}2) CM 10.4 8.6 6.9 5.0 7.9 Elongation @ MD 598% 588% 403% 329% 362% 23° C. (%) CM 435% 420% 287% 188% 238% Tear MD 6.1 6.0 5.7 4.1 7.5 (kgf/cm) CM 4.7 4.5 4.4 2.8 4.9 Therm Stability MD −14.9%  −10.9%  −15.1%  −13.1%  −18.8%  10 min @ 160° C. CM −7.8%  −6.6%  −5.1%  −11.9%  −11.7%  (% Shrinkage) Therm Stability MD −1.5%  −1.3%  −1.9%  −1.1%  −1.2%  1 hr @ 120° C. CM −1.4%  −1.4%  −1.3%  −0.9%  −0.8%  (% Shrinkage) Draw Ratio (H:D) 0.8 0.8 0.8 0.8 0.8 Orange Peel PASS PASS PASS PASS PASS Tensile @ 120° C. MD 3.9 2.9 2.6 1.9 2.8 (kgf/cm{circumflex over ( )}2) CM 2.3 1.8 1.5 1.0 1.4 Elongation @ MD 812% 926% 786% 440% 807% 120° C. (%) CM 435% 515% 400% 247% 326% Modulus @ MD 4.3 6.4 5.7 6.1 10.9 120° C. 100% CM 4.2 4.6 4.6 3.6 5.1 (kgf/cm{circumflex over ( )}2) Tensile @ 160° C. MD 0.95 0.64 0.51 0.48 0.5 (kgf/cm{circumflex over ( )}2) CM 0.64 0.46 0.33 0.27 0.3 Elongation @ MD 217% 210% 199% 163% 176% 160° C. (%) CM 177% 174% 164% 133% 135% Modulus @ MD 0.68 0.60 0.65 0.87 0.92 160° C. 100% CM 0.62 0.52 0.45 0.43 0.47 (kgf/cm{circumflex over ( )}2)

(34) As shown in TABLE 1B, the foam samples represent suitable performance specifications for an automotive interior trim molded foam component, for example.

Example 1—% Light Transmittance Vs. Basis Weight of Foam

(35) Foam samples listed in TABLE 2 below were produced according to the formulations of TABLE 1A to have differing basis weights and were each tested for % light transmittance according to JIS K 7361-1 as described previously.

(36) TABLE-US-00003 TABLE 2 Basis % Gauge Density Weight Transmittance (in) (pcf) (lb/sq in) Cream PP 1 33% 0.080 2.5 0.00012 (<1 atm) 2 14% 0.059 5.0 0.00017 3  9% 0.110 3.0 0.00019 4 15% 0.080 4.2 0.00019 White PP 1 34% 0.070 2.0 0.00008 (<1 atm) 2 27% 0.080 2.5 0.00012 3 23% 0.110 2.0 0.00013 4 27% 0.100 4.2 0.00024 5 20% 0.148 3.0 0.00026 6 18% 0.161 3.0 0.00028 White PE 1 32% 0.031 5.0 0.00009 (<1 atm) 2 24% 0.080 2.0 0.00009 3 31% 0.031 6.0 0.00011 4 26% 0.125 1.5 0.00011 5 24% 0.118 2.0 0.00014 6 22% 0.125 2.0 0.00014 7 26% 0.063 4.0 0.00015 8 25% 0.140 2.0 0.00016 9 14% 0.250 1.5 0.00022 10 23% 0.094 4.0 0.00022 11 20% 0.188 2.0 0.00022 12 21% 0.063 6.0 0.00022 13 30% 0.063 6.0 0.00022 14 16% 0.125 4.0 0.00029 15 14% 0.250 2.0 0.00029 16 16% 0.094 6.0 0.00033 17 10% 0.125 6.0 0.00043 18 17% 0.125 6.0 0.00043

(37) As shown by the results of TABLE 2 and the corresponding graph of FIG. 1, color affected the transmittance of light, with the white colored sample having better light transmittance than the cream colored sample having the same polypropylene (PP) resin. Further, the lower the basis weight of the foam samples, the better the light transmittance property observed. The white PE sample also showed the same trend in relation to basis weight, proving that PE behaves similarly to PP. Although light transmittance of up to 34% is shown in TABLE 2, it may be appreciated that foams having a light transmittance value of higher, including about 35% to about 50%, may be achieved using the various techniques, alone or in combination, as taught in the present disclosure including below. For example, White PP Sample 1 in TABLE 2 could be extruded at a higher air pressure to adjust the light transmittance to be higher. Further, the basis weight of the foam can be progressively lowered to increase light transmittance, such as down to about 0.00005 lb/in.sup.2.

Example 2—% Light Transmittance Vs. Color of Foam & Extrusion Conditions

(38) Foam samples of different colors listed in TABLE 3 and TABLE 4 below were prepared by the addition of colorants to the White PE formulation of TABLE 1A (<1 atm), and then tested for overall light transmittance at different basis weights, including using a HunterLab color spectrophotometer as described previously to measure L, a and b color solid values, with the “L” value for each scale indicating the level of light or dark, the “a” value redness or greenness, and the “b” value yellowness or blueness. All samples aside from the Open Air Green were extruded at (<1 atm).

(39) TABLE-US-00004 TABLE 3 % Den- Basis Transmit- sity Weight tance (pcf) (lb/sq in) L a b Open Air 10%  2.0 0.00014 65.27 −10.88 25.31 Green Ocean Blue 2% 2.0 0.00014 49.16 −14.37 −28.46 White 21%  2.0 0.00014 81.89 −0.66 0.31 Orange 6% 2.0 0.00009 55.63 39.39 22.07 Brown/Tan 0% 2.0 0.00029 57.08 5.11 14.85 Silver Grey 0% 2.0 0.00029 53.36 0.36 2.72 Natural 23%  2.0 0.00013 73.91 −0.50 7.15 Red 5% 2.5 0.00011 45.37 47.73 15.48 Green 3% 2.5 0.00011 55.88 −15.27 12.75 Indigo 0% 4.0 0.00015 25.59 −2.55 −20.61 Turquoise 0% 4.0 0.00029 53.02 −35.32 −4.26 Yellow 20%  4.0 0.00029 72.56 −4.70 41.23

(40) TABLE-US-00005 TABLE 4 % Basis Wt L a b Transmittance (lb/sq in) Cream 77.19 4.96 16.12 14% 0.00017 71.39 1.86 12.83  9% 0.00027 White 89.55 −1.00 15.62 34% 0.00008 88.14 −0.14 14.12 23% 0.00013 91.39 −1.47 10.80 27% 0.00024 90.32 −0.80 13.82 20% 0.00026 86.62 0.58 16.34 18% 0.00028 Orange 56.67 44.34 23.05  6% 0.00009 Yellow 73.77 −4.60 41.77 20% 0.00029 Army Green 56.51 −15.60 12.70  3% 0.00011 Ocean Blue 50.38 −14.71 −29.24  2% 0.00014

(41) As shown by the results of TABLE 3 and the corresponding graph of FIG. 2, comparing Open Air Green against the colored foams (<1 atm) showed that extruding at atmospheric pressure rather than at less than atmospheric pressure results in better % light transmittance. It was also found that natural, white, and yellow all had great % transmittance compared to other colors. Thus, creating an open-air extruded foam in natural, white, or yellow yields a large improvement in % transmittance.

(42) As shown by the results of TABLE 4 and the corresponding graphs of FIGS. 3A, 3B and 3C, the measured “L” value of foam had a direct relationship with % light transmittance across basis weights, with the higher the L value the higher the % transmittance (FIG. 3A), whereas there was no direct relationship with % light transmittance observable between the “a” value (FIG. 3B) and the “b” value (FIG. 3C) across basis weights, indicating that the relative redness versus greenness or yellowness versus blueness of the foam was not consequential to the % light transmittance. Accordingly, it may be appreciated that adjustment of the “L” value of the produced foam can also be used to increase or decrease % light transmittance as needed, in combination with other factors including but not limited to color of the foam and extrusion air pressures, including to achieve % light transmittance ranges beyond what was explicitly demonstrated in TABLES 3 and 4.

Example 3—% Light Transmittance Vs. Extrusion Air Pressure & Cell Size

(43) Foam samples listed in TABLE 5 below were measured for % light transmittance based on extrusion at different air pressures and basis weights to yield foam samples of different cell sizes. The Cream PP 2 formulation was subjected to the increased extrusion air pressures listed in TABLE 5 below.

(44) TABLE-US-00006 TABLE 5 % Basis Actual Trans- Density Weight Pressure Cell Size mittance (pcf) (lb/sq in) (psi) (microns) Under Vacuum 23% 3.2 0.00011 1.68 80 Open Air 33% 3.3 0.00012 14.7 153 +10 psi 33% 3.3 0.00012 24.7 160 +20 psi 32% 3.5 0.00013 34.7 150 +40 psi 22% 7.8 0.00022 54.7 123

(45) As shown by the results of TABLE 5 and the corresponding graphs of FIGS. 4A, 4B and 4C, as the size of the cells increased, the light transmittance improved due to less material such as cell walls obstructing the light's path (see, e.g., FIG. 4A). As shown by the graph of FIG. 4B, cell size increased as more air pressure was applied to the foam extrusion process, however, after about 10-20 psi, cell size was negatively affected. As shown in the graph of FIG. 4C, % light transmittance increased with increasing pressure (psi) which also corresponded to cell size, until about 10-20 psi where cell size was negatively affected along with % light transmittance. Accordingly, it may be appreciated that % light transmittance of the foam can be tailored by controlling cell size as another factor alone or in combination with the additional techniques taught by the present disclosure, including to achieve % light transmittance ranges beyond what was explicitly demonstrated in TABLE 5.

Example 4—% Light Transmittance Vs. Cell Wall Thickness

(46) Foam samples listed in TABLE 6 below were measured for % light transmittance based on extrusion at different air pressures and basis weights to yield foam samples of different cell wall thicknesses. The Cream PP 2 formulation was subjected to the increased extrusion air pressures listed in TABLE 6 below. Total wall thickness was calculated as the average number of cell walls multiplied by the average individual wall thickness (as measured in microns) from a first surface to a second surface of the foam (i.e. through the foam thickness as light would be transmitted). The total wall thickness to gauge ratio was calculated by dividing the total wall thickness by the gauge of the foam.

(47) TABLE-US-00007 TABLE 6 Total Wall Basis Actual Thickness % Density Weight Pressure to Gauge Transmittance (pcf) (lb/in{circumflex over ( )}2) (psi) Ratio Under Vacuum 23% 3.2 0.00011 1.68 0.496 Open Air 33% 3.3 0.00012 14.7 0.303 +10 psi 33% 3.3 0.00012 24.7 0.256 +20 psi 32% 3.5 0.00013 34.7 0.285 +40 psi 22% 7.8 0.00022 54.7 0.315

(48) As shown by the results of TABLE 6 and the corresponding graphs of FIGS. 5A and 5B, as the total wall thickness to gauge ratio decreases, the % light transmittance improved due to less material obstructing the light's path (see, e.g., FIG. 5A). As shown in FIG. 5B, the distance of material that the light is required to travel through with respect to the foam gauge decreased as the extrusion air pressure increased. As shown in FIG. 4C and as described earlier, % light transmittance increased with increasing pressure (psi) which corresponded to cell size and also less cell wall thickness with respect to the foam gauge, until about 10-20 psi where cell size was negatively affected along with % light transmittance. Accordingly, it may be appreciated that % light transmittance of the foam can be tailored by controlling the total wall thickness to gauge ratio of the foam as another factor alone or in combination with the additional techniques taught by the present disclosure, including to achieve % light transmittance ranges beyond what was explicitly demonstrated in TABLE 6.

Example 5—Effect of Extrusion Air Pressure on Foam Color

(49) Foam samples listed in TABLE 7 below foamed at different extrusion air pressures were measured using a HunterLab color spectrophotometer to measure L, a and b color solid values as described previously.

(50) TABLE-US-00008 TABLE 7 Actual Pressure L a b (psi) Under Vacuum 71.88 1.27 9.89 1.68 Open Air 67.65 1.17 10.04 14.7 +10 psi 66.65 0.88 9.66 24.7 +20 psi 66.37 1.18 10.01 34.7 +40 psi 74.59 6.18 15.42 54.7

(51) As shown by the results of TABLE 7 and the corresponding graph of FIG. 6, as the extrusion air pressure increased, the “L” value decreased, meaning the foam was getting darker while the “a” and “b” values were unaffected.

Example 6—% Light Transmittance Vs. Foaming Agent Diameter

(52) Foam samples listed in TABLE 8 below were measured for % light transmittance based on producing foam samples using a foaming agent (FA) having different average particle diameters in the Cream PP 2 formulation.

(53) TABLE-US-00009 TABLE 8 FA Total Wall % Diameter Cell Size Thickness to Sample Name Transmittance (microns) (microns) Gauge Ratio 12 microns 21% 12 259 0.416 15 microns 22% 15 323 0.356 20 microns 26% 20 464 0.327

(54) As shown by the results of TABLE 8 and the corresponding graphs of FIGS. 7A, 7B and 7C, a larger average foaming agent diameter resulted in a larger cell size (FIG. 7A), as the foaming agent diameter increased, the wall thicknesses decreased (FIG. 7B), and consequently the larger the foaming agent diameter, the better % light transmittance was achieved (FIG. 7C). Accordingly, it may be appreciated that % light transmittance of the foam can be tailored by controlling the foaming agent diameter as another factor alone or in combination with the additional techniques taught by the present disclosure, including to achieve % light transmittance ranges beyond what was explicitly demonstrated in TABLE 8.

Example 7—Trial Results 1

(55) Foam samples were further optimized according to the formulation for PP Trials in TABLE 1A to target improved % light transmittance for the automotive interior trim market.

(56) TABLE-US-00010 TABLE 9 Basis Cell Total Wall % Density Weight Size Thickness to Transmittance (pcf) (lb/sq in) (microns) Gauge Ratio L a b Cream PP (<1 atm) 12% 3.94 0.00027 200 0.356 71.90 2.68 12.19 White PP (<1 atm) 19% 3.88 0.00027 195 0.350 80.97 −1.07  9.63 Open Air White PP 29% 3.85 0.00027 429 0.304 73.00 −1.09  9.11 1 (@ 1 atm) Open Air White PP 23% 2.66 0.00018 279 0.179 77.54 −0.61 11.63 2 (@ 1 atm) Open Air White PP 33% 4.33 0.00016 323 0.220 78.52 −0.82 11.82 3 (@ 1 atm)

(57) As shown by the results of TABLE 9 and the corresponding graphs of FIGS. 8A, 8B and 8C, the color of the foam had no effect on the cell size though the open air sample generated much larger cells (FIG. 8A), and the color of the foam likewise had no effect on the cell wall thickness but the open air sample formed thinner cell walls than standard samples extruded below atmospheric pressure (FIG. 8B). As demonstrated by the trial results, utilizing the techniques taught by the present disclosure % light transmittance of a standard grade foam Cream PP compatible with the automotive market was able to be progressively increased from 12% to 33%, however this was not considered to be a maximum increase as other techniques can be utilized as demonstrated to further increase % light transmittance values, such as to about 50%. With respect to FIG. 8C, the Cream PP versus White PP resulted in an increase in light transmittance of 7%, and then White PP to Open Air White PP 1 resulted in a further increase in light transmittance of 10%, thus resulting in a total increase in light transmittance of 17% or about 2.5 times compared to the Cream PP samples.

Example 8—Trial Results 2

(58) Foam samples were further optimized according to the formulation for PP Trials in TABLE 1A to target improved % light transmittance for the automotive market, and then compared with the Cream PP and White PP samples across basis weights.

(59) TABLE-US-00011 TABLE 10 Basis % Gauge Density Weight Transmittance (in) (pcf) (lb/sq in) Cream PP 1 33% 0.080 2.5 0.00012 2 14% 0.059 5.0 0.00017 3  9% 0.110 3.0 0.00019 4 15% 0.080 4.2 0.00019 White PP 1 34% 0.070 2.0 0.00008 2 27% 0.080 2.5 0.00012 3 23% 0.110 2.0 0.00013 4 27% 0.100 4.2 0.00024 5 20% 0.148 3.0 0.00026 6 18% 0.161 3.0 0.00028 PP Trials Cream PP 12% 0.1196 3.94 0.00027 (<1 atm) White PP 19% 0.1194 3.88 0.00027 (<1 atm) Open Air 29% 0.123 3.85 0.00027 White PP 1 (@ 1 atm) Open Air 23% 0.117 2.66 0.00018 White PP 2 (@ 1 atm) Open Air 33% 0.065 4.33 0.00016 White PP 3 (@ 1 atm)

(60) As shown by the results of TABLE 10 and the corresponding graphs of FIG. 9, the Open Air White PP outperformed all other PP samples for each corresponding basis weight.

(61) According to the present disclosure, the light transmittance of foam may be improved and/or controlled and tailored to a desired range suitable for a wide variety of illuminated end-use applications through the appropriate selection and control of various parameters including cell size, cell wall thickness, total cell wall thickness to gauge ratio, color (including L value), and basis weight in view of the teachings and specific guidance provided herein. The present disclosure is the first to enable producing such a foam through the teachings of appropriate methods including proper selection of foaming agent diameter, extrusion air pressures and compatible formulations, as non-limiting examples.

(62) While the invention has been described with reference to exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.